3500 plenum question

[Superdave]

So i pulled off my plenum today for the hell of it and remembered something that i wanted to do back when i built the engine. In the pic you can see the "ring" that's right behind the TB flange. IIRC the bottom hole there was for the EGR or something which was removed and welded shut on the outside.. but the hole and ring remain.




I've seen it done in other applications but what do you guys think about filling those areas with JB-Weld or something to get rid of any possible tubulance?

Soon that inlet will be ported to either 70 or 75mm so i'd like it as smooth as possible.

Other ideas?

Thanks,
Dave

[ForcedFirebird]

If you have a TIG, fill it with metal. If you don't have a TIG, I would sugges Durafix.

I just don't like the idea of epoxy being in a motor.

[geldartb]

i wanted to do this to my 05 3400 plenum too. but i always thought of what would happen if the jbweld didnt hold and went into the engine.

with the 3400 as you might know on the 00+ you get the huge bump and depression where the egr comes in the kneck.

have you had any experience with the durafix stuff.

[onefastV6]

From expierence, do not use JB weld or any other epoxy.....

On my original 3500 plenum the neck was ground too thin, leaving a hole in plenum. So what was done was the plenum was cleaned in a parts washer, the inside of the plenum neck was roughed up and a industral epoxy that a machine shop recommended was placed over the hole.

I went to start my car one day and it just back fired.....huge vac leak due to the epoxy coming off. Luckily the piece was large and did not get sucked into the engine.

The problem is that traces of oil build up in the plenum, which gets soaked up in the porous aluminum, eventually losening the epoxy. The only safe solution would be to TIG weld it.

[Mars]

Once you port to 70mm, that "lip" will be gone...



See what I mean ...? All smooth besides one hole in the middle. (mines always full of oil, haha, I need a catch tank)

[geldartb]

what throttle body is that. i imagine it involves an adapter of some sort.

ive already got a 65mm throttlebody so i good for size. im gonna take it off the car and do some more smoothing inside it over the winter.

i dont need the hole anymore no more egr for my car.

anyone know of anyone that has used the durafix stuff or used it themselves.

[ForcedFirebird]

It's just a standard brazing material...

http://www.aluminumrepair.com/video_new.asp

[Superdave]

Once you port to 70mm, that "lip" will be gone...



See what I mean ...? All smooth besides one hole in the middle. (mines always full of oil, haha, I need a catch tank)

Aah.. i should have thought about that.


Guess i'll wait and see what happens after i get a new TB.

[Mars]

It's a Ford Racing unit 70mm, I think it's from a 4.6L Mustang. I got it on e-bay for like 50$ shipped.

It bolts on using 2 holes, and it's 100% leak proof with only 2 bolts in it (one each corner)

I had to get a remote IAC motor setup (bought it here) I am using the Ford TPS, and it works fine. Been on that setup for 3 years now, I made a custom gasket using universal gasket material, and it's 100% leak free with only 2 bolts holding it on.

[PCGUY112887]

I too wanted to remove this, good thing I didn't fill it with epoxy!

[SappySE107]

Well, people have used the epoxies with success as well. The key is cleaning and baking the part to get the oil out of the pores. I haven't had any luck with the durafix but it would be cool if it would work for me once:P Stuff looks like it would be excellent other than having to heat up the part to 700 degrees.

[Chris88CL]

It's a Ford Racing unit 70mm, I think it's from a 4.6L Mustang. I got it on e-bay for like 50$ shipped.

It bolts on using 2 holes, and it's 100% leak proof with only 2 bolts in it (one each corner)

I had to get a remote IAC motor setup (bought it here) I am using the Ford TPS, and it works fine. Been on that setup for 3 years now, I made a custom gasket using universal gasket material, and it's 100% leak free with only 2 bolts holding it on.

More info on the remote IAC motor setup??

[bszopi]

More info on the remote IAC motor setup??

Something Marty and I designed up a couple years ago when the 3500 plenum first because available. I know Marty made a couple and sold them, but with a plan of aluminum, it's pretty easy to fab up. Just see the attached PDF design sheet.

You can also see pics in the Gallery... http://www.60degreev6.com/gallery/br...hp?c=17&userid=

[ForcedFirebird]

It's a Ford Racing unit 70mm, I think it's from a 4.6L Mustang. I got it on e-bay for like 50$ shipped.

It bolts on using 2 holes, and it's 100% leak proof with only 2 bolts in it (one each corner)

I had to get a remote IAC motor setup (bought it here) I am using the Ford TPS, and it works fine. Been on that setup for 3 years now, I made a custom gasket using universal gasket material, and it's 100% leak free with only 2 bolts holding it on.

Did those two bolts line up with the holes on the 3500 plenum? Seems like a 70mm would work well considering some people who used 75mm said they were a bit too big, and Dave is concerned about 65 being too small.

[IsaacHayes]

Stock mustang V8 TB is 65mm. Just the IAC and linkage issue. But for you FF the linkage might work out since you need rear pull.